Kinetic and Mechanistic Study of Polycarbodiimide Formation from 4,4′-Methylenediphenyl Diisocyanate

In the polyurethane industry, catalytically generated carbodiimides can modify the properties of isocyanate and, thus, the resulting foams. In this work, a kinetic reaction study was carried out to investigate the formation of a simple, bifunctional carbodiimide from a widely used polyurethane raw material: 4,4'-methylenediphenyl diisocyanate (MDI). The experimental section outlines a catalytic process, using a 3-methyl-1-phenyl-2-phospholene-1-oxide (MPPO) catalyst in ortho-dichlorobenzene (ODCB) solvent, to model industrial circumstances. The reaction produces carbon dioxide, which was observed using gas volumetry at between 50 and 80 °C to obtain kinetic data. A detailed regression analysis with linear and novel nonlinear fits showed that the initial stage of the reaction is second-order, and the temperature dependence of the rate constant is k(T)=(3.4±3.8)‧106⋅e-7192±389T. However, the other isocyanate group of MDI reacts with new isocyanate groups and the reaction deviates from the second-order due to oligomer (polycarbodiimide) formation and other side reactions. A linearized Arrhenius equation was used to determine the activation energy of the reaction, which was E_a = 60.4 ± 3.0 kJ mol^-1 at the applied temperature range, differing by only 4.6 kJ mol^-1 from a monoisocyanate-based carbodiimide. In addition to experimental results, computationally derived thermochemical data (from simplified DFT and IRC calculations) were applied in transition state theory (TST) for a comprehensive prediction of rate constants and Arrhenius parameters. As a result, it was found that the activation energy of the carbodiimide bond formation reaction from theoretical and experimental results was independent of the number and position of isocyanate groups, which is consistent with the principle of equal reactivity of functional groups.